Methods and apparatus for transporting substrate carriers

ABSTRACT

According to a first aspect, a first conveyor system is provided that is adapted to deliver substrate carriers within a semiconductor device manufacturing facility. The first conveyor system includes a ribbon that forms a closed loop along at least a portion of the semiconductor device manufacturing facility. The ribbon is adapted to (1) be flexible in a horizontal plane and rigid in a vertical plane; and (2) transport a plurality of substrate carriers within at least a portion of the semiconductor device manufacturing facility. Numerous other aspects are provided, as are systems, methods and computer program products in accordance with these and other aspects.

The present application claims priority from U.S. Provisional PatentApplication Ser. No. 60/443,087, filed Jan. 27, 2003, which is herebyincorporated by reference herein in its entirety.

FIELD OF THE INVENTION

The present invention relates generally to semiconductor devicefabrication systems, and is more particularly concerned withtransportation of substrate carries within a fabrication facility.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is related to the following commonly-assigned,co-pending U.S. Patent Applications, each of which is herebyincorporated by reference herein in its entirety:

-   U.S. patent application Ser. No. 10/650,310, filed Aug. 28, 2003 and    titled “System For Transporting Substrate Carriers”;-   U.S. patent application Ser. No. 10/650,312, filed Aug. 28, 2003 and    titled “Method and Apparatus for Using Substrate Carrier Movement to    Actuate Substrate Carrier Door Opening/Closing”;-   U.S. patent application Ser. No. 10/650,481, filed Aug. 28, 2003 and    titled “Method and Apparatus for Unloading Substrate Carriers from    Substrate Carrier Transport Systems”;-   U.S. patent application Ser. No. 10/650,479, filed Aug. 28, 2003 and    titled “Method and Apparatus for Supplying Substrates to a    Processing Tool”;-   U.S. Patent Application Ser. No. 60/407,452, filed Aug. 31, 2002 and    titled “End Effector Having Mechanism For Reorienting A Wafer    Carrier Between Vertical And Horizontal Orientations”;-   U.S. Patent Application Ser. No. 60/407,337, filed Aug. 31, 2002,    and titled “Wafer Loading Station with Docking Grippers at Docking    Stations”;-   U.S. patent application Ser. No. 10/650,311, filed Aug. 28, 2003 and    titled “Substrate Carrier Door having Door Latching and Substrate    Clamping Mechanism”;-   U.S. patent application Ser. No. 10/650,480, filed Aug. 28, 2003 and    titled “Substrate Carrier Handler That Unloads Substrate Carriers    Directly From a Moving Conveyor”;-   U.S. Provisional Application Ser. No. 60/443,153, filed Jan. 27,    2003, and titled “Overhead Transfer Flange and Support for    Suspending Wafer Carrier”;-   U.S. Provisional Application Ser. No. 60/443,001, filed Jan. 27,    2003, and titled “Systems and Methods for Transporting Wafer    Carriers Between Processing Tools”; and-   U.S. Provisional Application Ser. No. 60/443,115, filed Jan. 27,    2003, and titled “Apparatus and Method for Storing and Loading Wafer    Carriers”.

FIELD OF THE INVENTION

The present invention relates generally to semiconductor devicefabrication systems, and is more particularly concerned withtransportation of substrate carriers within a fabrication facility.

BACKGROUND OF THE INVENTION

Manufacturing of semiconductor devices typically involves performing asequence of procedures with respect to a substrate such as a siliconsubstrate, a glass plate, etc. These steps may include polishing,deposition, etching, photolithography, heat treatment, and so forth.Usually a number of different processing steps may be performed in asingle processing system or “tool” which includes a plurality ofprocessing chambers. However, it is generally the case that otherprocesses are required to be performed at other processing locationswithin a fabrication facility, and it is accordingly necessary thatsubstrates be transported within the fabrication facility from oneprocessing location to another. Depending upon the type of semiconductordevice to be manufactured, there may be a relatively large number ofprocessing steps required, to be performed at many different processinglocations within the fabrication facility.

It is conventional to transport substrates from one processing locationto another within substrate carriers such as sealed pods, cassettes,containers and so forth. It is also conventional to employ automatedsubstrate carrier transport devices, such as automatic guided vehicles,overhead transport systems, substrate carrier handling robots, etc., tomove substrate carriers from location to location within the fabricationfacility or to transfer substrate carriers from or to a substratecarrier transport device.

For an individual substrate, the total fabrication process, fromformation or receipt of the virgin substrate to cutting of semiconductordevices from the finished substrate, may require an elapsed time that ismeasured in weeks or months. In a typical fabrication facility, a largenumber of substrates may accordingly be present at any given time as“work in progress” (WIP). The substrates present in the fabricationfacility as WIP may represent a large investment of working capital,which tends to increase the per substrate manufacturing cost. It wouldtherefore be desirable to reduce the amount of WIP for a given substratethroughput for the fabrication facility. To do so, the total elapsedtime for processing each substrate should be reduced.

Previously incorporated U.S. patent application Ser. No. 10/650,310,filed Aug. 28, 2003, entitled “System for Transporting SemiconductorSubstrate Carriers”, discloses a substrate carrier transport system thatincludes a conveyor for substrate carriers that is intended to beconstantly in motion during operation of the fabrication facility whichit serves. The constantly moving conveyor may facilitate transportationof substrates within the fabrication facility so as to reduce the total“dwell” time of each substrate in the fabrication facility; therebyreducing WIP, and cutting capital and manufacturing costs. Improveddesigns and methods of operation for such conveyors would be desirable.

SUMMARY OF THE INVENTION

According to a first aspect of the invention, a first conveyor system isprovided that is adapted to deliver substrate carriers within asemiconductor device manufacturing facility. The first conveyor systemincludes a ribbon that forms a closed loop along at least a portion ofthe semiconductor device manufacturing facility. The ribbon is adaptedto (1) be flexible in a horizontal plane and rigid in a vertical plane;and (2) transport a plurality of substrate carriers within at least aportion of the semiconductor device manufacturing facility.

In a second aspect of the invention, a second conveyor system isprovided that is similar to the first conveyor system. In addition tothe features of the first conveyor system, in the second conveyorsystem, the ribbon is adapted to continuously rotate; and a plurality ofsupports are rigidly coupled to the ribbon. Each support is adapted tosupport and transport a substrate carrier within at least a portion ofthe semiconductor device manufacturing facility. The second conveyorsystem also includes (1) one or more driving wheels adapted to contactthe ribbon and to rotate the ribbon; (2) one or more constraining wheelsadapted to contact the ribbon and to reduce lateral motion of the ribbonas it rotates; and (3) one or more support wheels adapted to support theribbon as the ribbon rotates. The one or more driving wheels, the one ormore constraining wheels and the one or more support wheels are eachadapted to be changed while the ribbon is in motion. Numerous otheraspects are provided, as are systems, methods and computer programproducts in accordance with these and other aspects of the invention.Each computer program product described herein may be carried by amedium readable by a computer (e.g., a carrier wave signal, a floppydisc, a compact disc, a DVD, a hard drive, a random access memory,etc.).

The methods and apparatus of the present invention provide for anefficient and reliable arrangement for transporting substrate carrierswithin one or more semiconductor device manufacturing facilities.

Other features and aspects of the present invention will become morefully apparent from the following detailed description of exemplaryembodiments, the appended claims and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A and 1B are exemplary perspective views of a portion ofrespective first and second exemplary ribbons of a conveyor configuredin accordance with the present invention.

FIG. 2 is a schematic view of a conveyor system comprising a ribbon inaccordance with the present invention that forms a simple loop within aportion of a semiconductor device manufacturing facility.

FIG. 3 is a schematic view of a conveyor system comprising a ribbon inaccordance with the present invention that forms a serpentine loop in aportion of a semiconductor manufacturing facility.

FIG. 4 is a schematic view of a conveyor system comprising ribbons inaccordance with the present invention that form simple and serpentineloops in portions of a semiconductor device manufacturing facility.

FIG. 5 is a perspective view of a third exemplary ribbon in accordancewith the present invention.

FIG. 6 is a close-up perspective view of the ribbon of FIG. 5.

FIG. 7 is a top plan view of the ribbon of FIG. 5.

FIG. 8 is a close-up top plan view of the ribbon of FIGS. 5 and 7.

FIG. 9 is a perspective view of a fourth exemplary ribbon in accordancewith the present invention comprising first and second ribbon sectionscoupled in parallel along their lengths.

FIG. 10 is a perspective view of a portion of the inventive ribbon ofFIG. 9, with a section removed to reveal adhesive strips running thelength of the ribbon.

FIG. 11 is a top plan view of the inventive ribbon of FIG. 9.

FIG. 12 is a perspective view of a fifth exemplary ribbon in accordancewith the present invention having respective vertical and horizontalportions formed from separate pieces of material.

FIG. 13A is a schematic side view of a portion of an exemplary supportsystem that may be employed to house, support, drive and/or constrain aribbon provided in accordance within the present invention.

FIG. 13B is a perspective view of an exemplary straight portion of aninventive support system for housing, driving, constraining and/orsupporting a portion of a ribbon provided in accordance with the presentinvention.

FIG. 14 is a side view of the inventive support system of FIG. 13.

FIGS. 15 and 16 are respective front and bottom plan views of aninventive driving wheel unit attached to a driving wheel unit support inaccordance with the present invention.

FIGS. 17 and 18 are respective rear and bottom plan views of aconstraining wheel unit in accordance with the present invention in a“lock” orientation.

FIGS. 19 and 20 are respective rear and bottom plan views of aconstraining wheel unit in accordance with the present invention in a“load” orientation.

FIGS. 21 and 22 are perspective views of alternative embodiments ofconstraining wheel units in accordance with the present invention.

FIG. 23 is a perspective view of a support wheel unit in accordance withthe present invention.

FIG. 24 is an exemplary embodiment of a sixth exemplary ribbon adaptedto transport a plurality of substrate carriers.

FIGS. 25A and 25B are a perspective view and a side view, respectively,of a seventh exemplary ribbon provided in accordance with the presentinvention.

FIG. 26 is a perspective view of an eighth exemplary ribbon provided inaccordance with the present invention.

DETAILED DESCRIPTION

In accordance with at least one aspect of the invention, an inventiveconveyor system is provided for transporting substrate carriers betweenone or more processing tools of a semiconductor device manufacturingfacility. The inventive conveyor system may include a ribbon ofstainless steel or a similar material that forms a closed loop within atleast a portion of the semiconductor device manufacturing facility andthat transports substrate carriers therein. By orienting the ribbon sothat a thick portion of the ribbon resides within a vertical plane and athin portion of the ribbon resides within a horizontal plane, the ribbonis flexible in the horizontal plane and rigid in the vertical plane.Such a configuration allows the inventive conveyor to be constructed andimplemented inexpensively. For example, the ribbon requires littlematerial to construct, is easy to fabricate and, due to its verticalrigidity/strength, can support the weight of numerous substrate carrierswithout supplemental support structure (such as rollers or other similarmechanisms used in conventional, horizontally-oriented belt-typeconveyor systems). Furthermore, the conveyor system is highlycustomizable because the ribbon may be bent, bowed or otherwise shapedinto numerous configurations due to its lateral flexibility.

In one or more embodiments of the invention, the ribbon of the conveyorsystem is rotated or “driven” using one or more driving wheels oranother driving mechanism, and the ribbon is supported using one or moresupporting wheels or another supporting mechanism. For example, thedriving wheels may contact and drive the ribbon along a vertical portionof the ribbon, and the supporting wheels may contact and support theribbon along a horizontal portion of the ribbon. In this manner, thedriving mechanism for the ribbon is decoupled from the supportingmechanism for the ribbon and each may be serviced independently. In oneparticular embodiment, each driving wheel and/or supporting wheel of theinventive conveyor system may be replaced while the ribbon is in motion(e.g., allowing the ribbon to be continuously rotated as describedfurther below). One or more constraining wheels or another constrainingmechanism may be employed to laterally stabilize and/or otherwise reducelateral motion of the ribbon during rotation. As with the driving wheelsand supporting wheels, in at least one embodiment of the invention, eachconstraining wheel may be replaced while the ribbon is in motion.Numerous other embodiments and/or aspects of the invention are describedbelow with reference to FIGS. 1A–23.

As used herein, a ribbon refers to a structure at least a portion ofwhich is generally flat (e.g., has a height and/or length that issignificantly larger than its width). A ribbon may be formed from one ormore materials and/or one or more pieces. For example, FIGS. 1A and 1Bare exemplary perspective views of a portion of a first ribbon 101 a anda second ribbon 101 b, respectively, of a conveyor (not separatelyshown) configured in accordance with the present invention. As shown inFIG. 1A, the first ribbon 101 a may be formed from a single piece ofmaterial, and/or may include both a ribbon-like, vertical portion 103 afor supporting substrate carriers and a horizontal portion 105 a forsupporting the first ribbon 101 a (as described further below). Thevertical portion 103 a of the first ribbon 101 a has a height H andlength L that are significantly larger than the width W of the firstribbon 101 a. Likewise, as shown in FIG. 1B, the second ribbon 101 b maybe formed from more than one piece. For example, the second ribbon 101 bincludes a first vertical portion 103 b and a second vertical portion103 b′, and a first horizontal portion 105 b and a second horizontalportion 105 b′. Although the cross-sectional shapes of the horizontalportions of ribbons 101 a and 101 b are shown as being flat andtriangular, respectively, it will be understood that other shapes may beemployed for the horizontal portion or portions of a ribbon inaccordance with the present invention.

Exemplary Conveyor Systems

FIG. 2 is a schematic view of a first exemplary conveyor system 106comprising a ribbon 101 c provided in accordance with the presentinvention that forms a simple loop 107 within a portion of asemiconductor device manufacturing facility 109. The ribbon 101 c maycomprise, for example, any of the inventive ribbons described herein.The ribbon 101 c transports substrate carriers (not shown) betweenprocessing tools 111, and comprises straight portions 115 and curvedportions 119 to form the (closed) loop 107.

FIG. 3 is a schematic view of a second exemplary conveyor system 121comprising a ribbon 101 d provided in accordance with the presentinvention that forms a serpentine loop 123 in a portion 125 of asemiconductor device manufacturing facility 127. The ribbon 101 dtransports substrate carriers (not shown) between substrate loadingstations 135 of a plurality of processing tools, such as processingtools 139, 143, 147 and 151. As shown in FIG. 3, ribbon 101 d comprisesnumerous straight portions 115 and curved portions 119 (all of which arenot labeled in FIG. 3) to form the serpentine (closed) loop 123. Theribbon 101 d may be similar to the ribbon 101 c of FIG. 3.

Each substrate loading station 135 may comprise, for example, anysuitable apparatus adapted to (1) receive a substrate carrier from theconveyor system 121; (2) unload a substrate from the substrate carrier;and/or (3) deliver the substrate to the processing tool coupled to thesubstrate loading station 135. One exemplary substrate loading stationthat may be employed is described in previously incorporated U.S. PatentProvisional Application Serial No. 60/407,337, filed Aug. 31, 2002,although other substrate loading stations may be employed. Eachsubstrate loading station 135 may be coupled to a processing tool and/orcomprise a load lock, factory interface or the like.

FIG. 4 is a schematic view of a third exemplary conveyor system 155comprising ribbons 101 e, 101 f, 101 g, 101 h and 101 j provided inaccordance with the present invention that form simple and serpentineclosed loops in respective portions 159, 163, 167, 171 and 175 of asemiconductor device manufacturing facility 177. Ribbons 101 e, 101 f,101 g and 101 h transport substrate carriers (not shown) betweensubstrate loading stations 179 of processing tools 139. Ribbon 101 jtransports substrate carriers (not shown) between ribbons 101 e, 101 f,101 g and 101 h. At the respective interfaces between ribbon 101 j andribbons 101 e, 101 f, 101 g and 101 h, transfer mechanisms 183 areprovided for transferring substrate carriers (not shown) from one ribbonto another and vice versa. Fewer or more transfer mechanisms than shownmay be employed. Ribbons 101 e, 101 f, 101 g, 101 h and 101 j allcontain straight portions and curved portions and form closed loops, butonly ribbons 101 e, 101 f, 101 g and 101 h form serpentine loops. Otherloop configurations may be employed. The ribbons 101 e–j may comprise,for example, any of the inventive ribbons described herein.

Exemplary Inventive Ribbons

FIG. 5 is a perspective view of a third exemplary ribbon 101 k providedin accordance with the present invention. Ribbon 101 k (or at least theportion of ribbon 101 k shown in FIG. 5) is formed from a continuous(single) piece of material. A vertical portion 103 k of ribbon 101 k hasa narrow width W compared to a height H and a length L of the verticalportion 103 k. A horizontal portion 105 k of ribbon 101 k is formed inpart by bends 187 and 191 in the material of the ribbon 101 k, andpresents a horizontal surface 193 by which the weight of ribbon 101 kmay be supported. Surface indicia, such as vertically-oriented slots 195and mounting features, such as holes 197, are provided on the verticalportion 103 k of ribbon 101 k, and are arranged at regular intervalsalong the length L of ribbon 101 k to respectively (1) identify thelocation of substrate carriers being transported by the ribbon 101 k (asdescribed below); and (2) provide a secure and/or rigid mountinglocation for supports or cradles adapted to support substrate carriersbeing transported by the ribbon 101 k (as described below). Othersurface indicia may be employed to identify substrate carrier location(e.g., two or more slots per substrate carrier location, other indiciashapes, reflective surfaces, etc.). Likewise other mounting features maybe employed for supporting substrate carriers.

FIG. 6 is a close-up perspective view of the ribbon 101 k of FIG. 5corresponding to circular window 199 of FIG. 5. As shown in FIG. 6, tabs203 formed at the end of the ribbon 101 k (near horizontal portion 105k) mate with and are inserted into insertion slots 207 formed in thevertical portion 103 k of the ribbon 101 k. Welds (not shown) are formedat the interface between the tabs 203 and insertion slots 207 to preventthe tabs 203 from backing out of the slots 207, and strain relief slots211 are formed through the ribbon 101 k next to the welds (not shown) toprovide strain relief at the site of the welds. Other methods ofattaching the horizontal portion 105 k of the ribbon 101 k to thevertical portion 103 k of the ribbon 101 k may be employed such asrivoted T sections.

Bending features such as bending slots 219 (e.g., laser or otherwisemachined cuts) are formed through horizontal portion 105 k, andstrain-relief openings 221 are formed near bend 187 of horizontalportion 105 k (adjacent bending slots 219) to relieve strain along bend187 of the horizontal portion 105 k when ribbon 101 k bends and/orflexes in a horizontal plane (as described further below).

FIG. 7 is a top plan view of the ribbon 101 k of FIGS. 5 and 6, and FIG.8 is a close-up top plan view of the ribbon 101 k of FIG. 7corresponding to circular window 223 of FIG. 7. As shown in FIGS. 7 and8, in at least one embodiment, the bending slots 219 through horizontalportion 105 k of ribbon 101 k are V-shaped and run perpendicular tobends 187 and 191 from the strain relief openings 221 (FIG. 6) locatedalong bend 187. Because bending slots 219 pass all the way throughhorizontal portion 105 k of ribbon 101 k, nothing in the structure ofthe horizontal portion 105 k of ribbon 101 k will prevent ribbon 101 kfrom bending or otherwise flexing in a horizontal plane perpendicular tothe vertical portion 103 k of the ribbon 101 k (FIG. 6), such as in the+x and −x directions in FIGS. 7 and 8. However, if bending slots 219were relatively narrow at bend 191, the extent to which ribbon 101 kcould bend in the +x direction would be much more limited. Due to theshape of bending slots 219 being roughly in the form of a “V”, a gap 227between edges 231 and 235 of bending slots 219 at bend 191 isproportionally much larger than the narrow gap 239 between edges 231 and235 of bending slots 219 at bend 187. As such, a concave right bend asviewed in FIGS. 7 and 8 (e.g., a bend in the +x direction) is nearly asunrestrained as is a concave left bend (e.g., a bend in the −xdirection). It will be understood that concave right bends are limitedto bends that cause edges 231 and 235 of bending slots 219 to touch,eliminating gap 227 and provoking mechanical interference.

Other configurations for providing the horizontal portion 105 k withlateral flexibility may be provided in place of or in addition to theV-shaped bending slots 219, such as uniform width bending slots orotherwise shaped slots or features. Exemplary dimensions and materialsfor the ribbon 101 k are described below.

FIG. 9 is a perspective view of a fourth exemplary ribbon 1011comprising first and second ribbon sections 1011′ and 1011″ coupled inparallel along their lengths. With reference to FIG. 9, a horizontalportion 1051 of ribbon 1011 comprises first and second horizontalportions 1051′ and 1051″, and a vertical portion 1031 of ribbon 1011comprises first and second vertical portions 1031′ and 1031″. Firsthorizontal portion 1051′ of first ribbon section 1011′ includes bends1871′ and 1911′, and bending features such as bending slots 2191′, andsecond horizontal portion 1051″ of second ribbon section 1011″ includesbends 1871″ and 1911″, and bending features such as bending slots 2191″.

FIG. 10 is a perspective view of a portion of ribbon 1011 of FIG. 9,with second ribbon section 1011″ removed to reveal adhesive strips 243a, 243 b and 243 c (e.g., two-sided tape) running the length of ribbon1011. Adhesive strip 243 a is placed along the top of ribbon 1011adjacent horizontal portion 1051, and secures the first horizontalportion 1051′ of first ribbon section 1011′ to the second horizontalportion 1051″ (FIG. 9) of second ribbon section 1011″ (FIG. 9). Adhesivestrip 243 b is placed along the middle of ribbon 1011, and adhesivestrip 243 c is placed along the bottom of ribbon 1011. Together,adhesive strips 243 b and 243 c secure the first vertical portion 1031′of first ribbon section 1011′ to the second vertical portion 1031″(FIG.9) of second ribbon section 1011″ (FIG. 9). Other locations for theadhesive strips 243 a–b may be employed.

Each adhesive strips 243 a–c may comprise, for example, one or morestrips of high-strength, two-sided tape such as VHB tape manufactured by3 M, or another suitable adhesive strip. Other numbers of adhesivestrips may be employed, as may other techniques for coupling the firstand second ribbon sections 1011′ and 1011″ of the ribbon 1011 (e.g.,welding, riveting, gluing or the like).

FIG. 11 is a top plan view of ribbon 1011 of FIG. 9. As shown in FIG.11, v-shaped bending slots 2191′ extend through horizontal portion 1051′of first ribbon section 1011′ and provide a first gap 2271′ at bend1911′ that is wider than a second gap 2391′ at bend 1871′. V-shapedbending slots 2191″ extend through horizontal portion 1051″ of secondribbon section 1011″ and provide a third gap 2271″ at bend 1911″ that iswider than a fourth gap 2391″ at bend 1871″. As with the bending slots219 of the third ribbon 101 k of FIGS. 5–8, the bending slots 2191′ and2191″ allow the fourth ribbon 1011 to bend and/or otherwise flex in ahorizontal plane perpendicular to the vertical portion 1011 of theribbon 1011 (e.g., in the +x and −x directions of FIG. 11). In at leastone embodiment of the invention, the gaps 2271′ and 2271″ may besubstantially equivalent in width, giving ribbon 1011 equivalent bendingranges in the +x and −x directions. Alternatively, the gaps 2271′ and2271″ may be different. Other configurations for providing thehorizontal portion 1051 with lateral flexibility may be employed inplace of or in addition to the V-shaped bending slots 2191′ and 2191″such as uniform width bending slots or otherwise shaped slots orfeatures. Exemplary dimensions and materials for the ribbon 1011 aredescribed below.

FIG. 12 is a perspective view of a fifth exemplary ribbon 101 m providedin accordance with the present invention having a vertical portion 103 mand a horizontal portion 105 m formed from separate pieces of material.In at least one embodiment of the invention, attachment features such asholes 247 in the vertical portion 103 m of the ribbon 101 m correspondto attachment features (e.g., holes 251) in the horizontal portion 105 mof the ribbon 101 m, enabling horizontal portion 105 m to be attached(e.g., bolted, riveted, or otherwise attached) to vertical portion 103 malong the length of the vertical portion 103 m. In another embodiment ofthe invention, the horizontal portion 105 m may be attached to thevertical portion 103 m via adhesion (e.g., using strips of adhesive tapeas previously described on one or both sides of the vertical portion 103m), welding, etc., (with or without the use of attachment features).

Horizontal portion 105 m may comprise separately attachable horizontalportion sections 255, shaped appropriately to permit lateral bending ofvertical portion 103 m without mechanical interference betweenhorizontal portion sections 255. For example, the horizontal portionsections 255 may be shaped so as to form gaps between adjacent portionsections 255, similar to the bending features of the ribbons 101 k, 101l of FIG. 5–11, when the horizontal portion sections 255 are attached tothe vertical portion 103 m of the ribbon 101 m. Any of the otherconfigurations described herein for providing lateral flexibility alsomay be employed.

Each horizontal section portion 255 comprises a first horizontal portion255 a adapted to extend horizontally from a first side of the verticalportion 103 m of the ribbon 101 m, and a second horizontal portion 255 badapted to extend horizontally from a second side of the verticalportion 103 m. The first and second horizontal portions 255 a–b may becoupled together and/or formed from a single (continuous) piece ofmaterial (as shown), or separate and/or formed from multiple pieces ofmaterial. Other shapes of horizontal section portions 255 than thatillustrated may be employed (e.g., triangular shapes). Further, two ormore of the horizontal section portions 255, the first horizontalportions 255 a and/or the second horizontal portions 255 b may be formedfrom a single (continuous) piece of material; and provided withappropriate bending features.

Vertical portion 103 m may also comprise separately attachable verticalportion sections 259. For example, each vertical portion section 259 maybe provided with a thinned region at an end of the vertical portionsection 259 that is to be coupled to another vertical portion section259. In this manner, the thinned regions of the vertical portionsections 259 may overlap, and be secured to one another via bolting,riveting, welding, adhesives or an other technique without significantlyincreasing the width and/or affecting the bending properties of theribbon 101 m. The horizontal portion sections 255 also may be employedto couple vertical portion sections 259 together (e.g., via bolts,rivets or the like which extend through two back-to-back horizontalportion sections 255 a and 255 b, via a clamping action when eachhorizontal section portion 255 is formed from a single (continuous)piece of material, etc.). Additional attachment features (e.g., holes247, 251) may be provided within the vertical portionsections/horizontal portion sections for this purpose (as shown atlocation 261 in FIG. 12).

In one embodiment of the invention vertical portion sections 259 can bemated along a diagonal or otherwise oriented seam 263 and secured atfeatures 267 (e.g., bolt or rivet holes through the vertical portionsections 259) at locations on vertical portion 103 m at which verticalportion sections 259 overlap. Where vertical portion sections 259overlap, the vertical portion sections can be half as thick as theoverall width of the vertical portion 103 m to maintain uniform bendingproperties along the length of vertical portion 103 m.

If a single piece of material is used to form the entire verticalportion 103 m of ribbon 101 m, the two ends of the vertical portion 103m can be secured as described above to form a continuous loop. Any ofthe other ribbons described herein may be similarly formed from singleor multiple vertical portion sections.

Exemplary embodiments for the ribbon 101 a–m of FIGS. 1A–12 will now bedescribed. It will be understood that the below listed embodiments aremerely exemplary, and that other materials, dimensions and/or otherparameters may be employed. For convenience, “ribbon 101” is employed torefer to any of the inventive ribbons described herein.

Selection of the material used for any of the ribbons 101 may be basedon numerous factors such as material strength, flexibility, fatiguerate, cost, etc. In one or more embodiments, at least the verticalportion 103 of each ribbon 101 is formed from stainless steel, such as301 half hard, 17-7 or another suitable stainless steel. The horizontalportion 105 of each ribbon 101 may be formed from the same, or in somecases a different material, than is employed to form the verticalportion 103 of the ribbon 101. Other suitable materials that may beemployed to form the ribbon include, for example, plastic having aninterior support structure such as stainless steel, or a similarmaterial.

Selection of the thickness of the vertical portion 103 of each ribbon101 also may be based on such factors as material strength, flexibility,fatigue rate, cost, etc. Additionally, and as described further below,numerous driving and/or constraining wheels may be employed to drive andreduce lateral motion of a ribbon as the ribbon rotates. As a ribbonpasses over (or between) such driving or constraining wheels, the ribbonmay deflect laterally (e.g., possibly increasing the difficulty ofsubstrate transfer operations, requiring larger tolerances for otherconveyor components, etc.). To reduce lateral deflections, the thicknessof the vertical portion 103 of a ribbon 101 may be increased. However,increasing ribbon thickness increases fatigue rate of the ribbon.Accordingly, a balance between lateral deflection amount and fatiguerate may be obtained through appropriate selection of material thicknessfor the vertical portion 103 of a ribbon 101. In one particularembodiment wherein the ribbon 101 is formed from stainless steel, avertical portion 103 thickness of between about 0.04–0.06 inches, andmore preferably about 0.05 inches, may be employed based on these and/orother considerations. In embodiments such as the second ribbon 101 b(FIG. 1B) and the fourth ribbon 1011 (FIG. 9) wherein two ribbonsections are coupled together, an overall vertical portion 103 thicknessof between about 0.04–0.06 inches of stainless steel, and morepreferably about 0.05 inches of stainless steel, may be employed. Notethat the adhesive strips 243 a–c may increase the overall thickness of avertical portion (e.g., by about 0.015 inches, depending on the adhesivestrip employed). (A thicker adhesive film may have improvedvibration/sound dampening, but may be more fragile.) As stated, othermaterials and/or other thicknesses for each ribbon 101 may be employed.

Selection of the overall height of a ribbon 101 may be based on a numberof factors such as that amount of the vertical portion 103 required toaccommodate the (1) horizontal portion 105 of the ribbon 101; and (2)any substrate carrier supports (described below) coupled to the ribbon101 (e.g., at mounting locations such as the holes 197 in FIG. 5). Otherfactors may include, for example, the size of the wheels employed toconstrain and/or drive the ribbon 101 (described below). In general, ashorter ribbon height reduces lateral curvature of a ribbon. In oneparticular embodiment wherein the horizontal portion 105 of a ribbon 101consumes about 0.5 inches of the vertical portion 103 of the ribbon 101,a ribbon height of about six inches is employed, although other ribbonheights may be used. Other horizontal portion heights also may beemployed.

Selection of the width of the horizontal portion 105 of a ribbon 101 maydepend on, for example, the width of the device employed to support theribbon (e.g., support wheel width, described below), the amount oflateral deviation of the ribbon 101 as it rotates, etc. In oneparticular embodiment, the overall width of the horizontal portion 105is about 1.5 inches (e.g., about 0.75 inches on each side of thevertical portion 103), although other dimensions may be employed.

Selection of the width of the bending features of the horizontal portion105 of a ribbon 101 may be based on, for example, width of thehorizontal portion 105 (e.g., distance the horizontal portion 105extends laterally from the vertical portion 103 of the ribbon), theamount the ribbon material may bend without being damaged and/orprematurely fatigued, the spacing between adjacent bending features,support wheel dimensions/wear resistance, and/or the like. In general,the larger the width of the bending feature (of a horizontal portion ofa ribbon), the more the ribbon may bend, and the more a supporting wheelmay wear during rotation of the ribbon. Further, a smaller spacingbetween adjacent bending features generally requires smaller bendingfeature width to obtain equivalent bending. Too small of a spacingbetween adjacent bending features, however, may increase ribbonmanufacturing costs and/or complexity, and may decrease reliability. Inone particular embodiment wherein a bending radius of about 36–48 inchesis desired for a stainless steel ribbon, a uniform bending feature widthof about 0.034 inches and a bending-feature-to-bending-feature spacingof about one inch may be employed. Other bending radii, bending featuresizes, and/or bending feature spacings may be provided.

Exemplary Support Systems for Inventive Ribbon

To form a conveyor system for transporting substrate carriers within asemiconductor device manufacturing facility employing one of theinventive ribbons 101 described herein (such as one of the conveyorsystems described previously with reference to FIGS. 2–4), the ribbonmust be supported and rotated. FIG. 13A is a schematic side view of aportion of an exemplary support system 269 that may be employed tohouse, support, drive and/or constrain a ribbon 101 (shown in phantom)within a conveyor system. In general, the support system 269 may (or maynot) surround an entire closed loop formed by the ribbon 101.

The portion of the support system 269 shown in FIG. 13A includes ahousing section 271 adapted to surround at least a portion of the ribbon101. For example, a first portion 272 a of the housing section 271 maysurround the horizontal portion 105 of the ribbon 101, and a secondportion 272 b of the housing section 271 may surround at least a portionof the vertical portion 103 of the ribbon 101. Many of such housingsections may be employed to house and/or support a ribbon within aconveyor system.

The housing section 271 includes one or more first openings 273 adaptedto allow at least one support wheel (not shown) to contact and supportthe ribbon 101 as the ribbon 101 rotates; and one or more secondopenings 275 adapted to allow at least one constraining wheel (notshown) to contact the ribbon 101 and to reduce lateral motion of theribbon 101 as the ribbon 101 rotates. The housing section 271 also mayinclude one or more third openings 277 adapted to allow a driving wheel(not shown) to contact the ribbon 101 and rotate the ribbon 101. Thenumber of support, constraining and/or driving wheels employed maydepend on a number of factors such as length of the housing section 271,whether the housing section 271 is straight or curved, whether thehousing section 271 is at a location at which substrate carrier transferoperations may occur, the amount of lateral wobble of the ribbon 101that can be tolerated within a conveyor system employing the housingsection 271, etc., as described further below.

The housing section 271 of the support system 269 may be supported byone or more housing supports 279. One or more shields 281 (only aportion of one shield 281 is shown in FIG. 13A) may be coupled to thehousing supports 279 and/or the housing section 271 so as to protectsubstrate carriers (such as substrate carrier 283 in FIG. 13A) beingtransported by the ribbon 101 and/or operators from the ribbon 101and/or substrate carriers being transported by the ribbon 101. Asstated, the housing section 271 may be straight or curved, depending onthe portion of the ribbon 101 that is being housed and/or supported bythe housing section 271.

FIGS. 13B and 14 are a perspective view and a side view, respectively,of an exemplary straight portion of an inventive support system 269 afor housing, driving, constraining and/or supporting a portion of asixth ribbon 101 n (FIG. 14) in accordance with the present invention.The sixth ribbon 101 n is similar to the first ribbon 101 a of FIG. 1A,and comprises a t-shaped ribbon having a horizontal portion and verticalportion formed from a single (continuous) piece of material. Any of theother ribbons described herein may be similarly housed, driven,constrained and/or supported by the support system 269 a.

Support system 269 a comprises a housing section 271 a, two or morehousing section supports 279 a adapted to support the housing section271 a, a driving wheel system 284 (which in the embodiment showncomprises two driving wheel units 285 attached to a driving wheel unitsupport 287 through which housing section 271 a is passed), and multiplesupport wheel units 289 and constraining wheel units 291 attached tohousing section 271 a. Fewer or more numbers of supports 279 a, drivingwheel units 285, support wheel units 289 and/or constraining wheel units291 may be employed.

At least a portion of ribbon 101 n (FIG. 14) is housed by and is allowedto pass through housing section 271 a. Ribbon 101 n (FIG. 14) in turnmay transport substrate carriers 283 a (FIG. 14) by the use of cradlesor other supports 292 (FIG. 14) as described further below. As describedpreviously with reference to FIG. 13A, housing section 271 a hasopenings (not shown) for allowing the wheels (not shown) of the drivingwheel units 285, support wheel units 289, and constraining wheel units291 to contact ribbon 101 n as the ribbon 101 n rotates (e.g., passesthrough housing section 271 a).

In at least one embodiment of the invention, the ends of housing section271 a may slide into supports 279 a and be secured therein by fasteners293 (e.g., bolts, screws or the like). Supports 279 a further providemounting features, e.g. slotted holes 295 or other features, that permitthe supports 279 a together with the housing section 271 a to be heldaloft, e.g., from the ceiling of a semiconductor device fabricationfacility.

In at least one embodiment of the invention, shields 281 a (only one ofwhich is shown in FIG. 13B) span the length of each side of housingsection 271 a between supports 279 a, and may be held in place, forexample, by supports 279 a (e.g., via support regions 297 formed on eachside of each support 279 a) and/or by the housing section 271 a. Eachshield 281 a is shaped such that substrate carriers 283 a (FIG. 14)being transported by the ribbon 101 n and supports or cradles 292 (FIG.14) supporting such carriers are shielded from any potential impact withother objects within the semiconductor device manufacturing facility.Shields 281 a may be screwed, bolted or otherwise held in place relativeto the supports 279 a and/or housing section 271 a as shown in FIG. 13B.

In at least one embodiment of the invention, each housing section 271 ais formed from a material having sufficient strength and rigidity tosupport the various components coupled to the housing section 271 a(e.g., the driving wheel units 285, the driving wheel unit support 287,the support wheel units 289 and/or the constraining wheel units 291) andthe ribbon 101 n. For example, each housing section 271 a may be formedof a material such as aluminum, plastic, etc. The housing sectionsupports 279 a and/or the driving wheel unit support 287 may be formedfrom a similar material (e.g., an aluminum casting).

The shields 281 a preferably are formed from a lightweight and/orinexpensive material such as aluminum, sheet metal, vacuformed plastic,etc., so as to reduce the overall weight and expense of the supportsystem 269 a. When the shields 281 a are formed of a material such asaluminum, one or more of the housing section supports 279 a may includean extended support region 297 that allows a shield 281 a to fit thereinand/or be supported between the supports 279 a despite thermally inducedlength variations of the shield. Such temperature induced length changesmay occur, for example, if the system 269 a is fabricated/tested at afacility having a different temperature than the semiconductor devicemanufacturing facility in which the system 269 a is eventuallyinstalled.

As shown in FIG. 14, housing section 271 a forms a first gap 301, withinwhich the horizontal portion 105 n of ribbon 101 n is housed and throughwhich the horizontal portion 105 n can pass. Housing section 271 a alsoforms a second gap 303, within which the vertical portion 103 n ofribbon 101 n is housed and through which the vertical portion 103 n canpass. The gaps 301, 303 of the housing section 271 a may be sized toaccommodate any of the ribbon configurations described previously, orany other ribbon configuration. As shown in FIG. 14, the housing section271 a also includes a third gap 305 sized to allow mounting hardware 307(for supporting each cradle/support 292) to be coupled to the verticalportion 103 n of the ribbon 101 n.

Each housing support 279 a forms an opening 309, through which avertical end portion of housing section 271 a is inserted. As stated,housing section 271 a may be secured in place within each support 279 aby fasteners 293 (e.g., by bolts or other fasteners that extend throughflanges of housing section 271 a). Exemplary embodiments of the drivingwheel units 285, the support wheel units 289 and the constraining wheelunits 291 are described below with reference to FIGS. 15–23.

Exemplary Inventive Driving Wheel System

FIGS. 15 and 16 are a front plan view and a bottom plan view,respectively, of an exemplary embodiment of the inventive driving wheelsystem 284 of FIG. 13B, referred to as driving wheel system 284 a inFIGS. 15 and 16. The driving wheel system 284 a may be similar to thedriving wheel system 284 of FIG. 13B and may include one or more drivingwheel units 285 a coupled to a driving wheel unit support 287 a. In theembodiment of FIGS. 15 and 16, however, only one driving wheel unit 285a is employed.

With reference to FIGS. 15 and 16, the driving wheel unit 285 a includesa motor 311 coupled to and adapted to rotate a rotating member 313(e.g., a wheel, gear, etc.) contained within a motor housing 315 coupledto the driving wheel unit support 287 a. The motor 311 may comprise, forexample, a conventional servo motor or other suitable motor capable ofrotating the rotating member 313 (and thus a ribbon 101 of an inventiveconveyor system as described below) at an approximately constant rate.

In the embodiment shown in FIGS. 15 and 16, the motor housing 315 iscoupled to the driving wheel unit support 287 a via a first pivot 317and a first latching mechanism 319 a (FIG. 16). When the first latchingmechanism 319 a is disengaged, the motor housing 315 may pivot toward oraway from the driving wheel unit support 287 a; and when the firstlatching mechanism 319 a is engaged, the motor housing 315 is heldstationary relative to the driving wheel support 287 a (as shown inFIGS. 15 and 16). Any suitable latching mechanism may be employed toengage/disengage the non-pivoting end of the motor housing 315 relativeto the driving wheel unit support 287 a. For example, the first latchingmechanism 319 a may comprise a ring/hoop 321 (coupled to the motorhousing 315) that engages/disengages a hook 323 (coupled to the drivingwheel unit 287 a) in response to movement of a handle 325. Any othersuitable configuration may be employed similarly.

The driving wheel unit support 287 a includes an opening 327 sized toallow a housing section 271 of support system 269 (FIG. 13A or 13B) topass therethrough, and may be coupled to the housing section 271 via anysuitable fastening mechanism (e.g., bolts, screws or the like, generallyrepresented by reference numeral 329 in FIG. 15). Other configurationsmay be employed. For example, the driving wheel unit support 287 a maybe adapted to reside on and/or couple to only one side of a housingsection.

The driving wheel unit support 287 a includes a first set of wheels 331a adapted to pass through an opening in a first side of a housingsection 271, such as opening 277 in FIG. 13A, and contact a first sideof a vertical portion 103 of a ribbon 101 contained therein (not shownin FIGS. 15 and 16). The driving wheel unit support 287 a also includesa second set of wheels 331 b adapted to pass through an opening, such asan opening 277, in a second side (opposite the first side) of the samehousing section 271 and contact a second side of the vertical portion103 of the ribbon 101. In this manner, the first and second sets ofwheels 331 a, 331 b limit lateral motion of the ribbon 101. Fewer ormore than two wheels per wheel set may be employed.

In the embodiment shown in FIGS. 15 and 16, the first set of wheels 331a are adapted to be contacted and driven by the rotating member 313. Thefirst set of wheels 331 a, in turn, may contact a vertical portion 103of a first side of a ribbon 101 that passes through the driving wheelunit support 287 a and drive (rotate) the ribbon 101. As stated, thesecond set of wheels 331 b are adapted to contact a second side of thevertical portion 103 of the ribbon 101 (opposite to the first side); andreduce lateral motion of the ribbon 101 due to contact with the firstset of wheels 331 a. In general, one or both sets of wheels 331 a, 331 bmay be motor driven.

The first set of wheels 331 a is coupled to the driving wheel unitsupport 287 a via a first pivot member 333 (FIG. 16) that is adapted topivot about a second pivot 335. The first pivot member 333 (and thus thefirst set of wheels 331 a) may be adapted to pivot toward or away fromthe second set of wheels 331 b as the motor housing 315 pivots toward oraway from the second set of wheels 331 b. For example, the first pivotmember 333 may be coupled to the motor housing 315 or biased (e.g., viaa spring) so as to move away from the second set of wheels 331 b whenmotor housing 315 pivots away from the second set of wheels 331 b.

Likewise, the second set of wheels 331 b is coupled to the driving wheelunit support 287 a via a second pivot member 337 (FIG. 16) that isadapted to pivot about a third pivot 339. A latching member 341, coupledto the driving wheel unit support 287 a via a fourth pivot 343 and asecond latching mechanism 319 b, may be employed to selectively pivotthe second pivot member 337 (and thus second set of wheels 331 b) awayfrom or toward the first set of wheels 331 a. The latching mechanism 319b may be similar to the latching mechanism 319 a, or any other suitablelatching mechanism may be employed. As stated, the second set of wheels331 b also may be driven, and configured to pivot with a driving wheelunit in a manner similar to that of the first set of wheels 331 a.

In operation, a ribbon 101 (not shown) may pass through the drivingwheel unit support 287 a (and a housing section 271) and may be driven(rotated) at an approximately constant speed by the first set of wheels331 a. Excessive lateral motion due to contact between the ribbon andthe first set of wheels 331 a is limited by the second set of wheels 331b. Assuming the ribbon is driven by more than one of the driving wheelsystems 284 a, the first set of wheels 331 a may be replaced while theribbon is in motion by (1) releasing the latching mechanism 319 a; (2)pivoting the motor housing 315 away from the first set of wheels 331 a;(3) pivoting the first set of wheels 331 a away from the ribbon; and (4)replacing the first set of wheels 331 a. The first set of wheels 331 amay then be brought back into contact with the ribbon. The second set ofwheels 331 b may be replaced while the ribbon is in motion via a similaroperation (employing the latching mechanism 319 b and the latchingmember 341). The first and second sets of wheels 331 a, 331 b (or anyother portions of the driving wheel system 284 a) may be replaced at thesame time or at different times.

Exemplary Inventive Constraining Wheel Units

FIGS. 17 and 18 are respective rear and bottom plan views of a firstexemplary embodiment of the constraining wheel unit 291 of FIG. 13B,referred to as constraining wheel unit 291 a in FIGS. 17 and 18, inwhich the constraining wheel unit 291 a is in a “lock” position withconstraining wheels extended. FIGS. 19 and 20 are respective rear andbottom plan views of the constraining wheel unit 291 a in a “load”position with constraining wheels retracted.

With reference to FIGS. 17–19, the constraining wheel unit 291 aincludes a housing 351 that is adapted to couple to an opening of ahousing section 271 of support system 269 (e.g., the second opening 275of housing section 271 in FIG. 13A, such as via one or more bolts,screws or other fasteners represented generally by reference numeral 353in FIGS. 17–19). The housing 351 houses a pair of constraining wheels355 that are adapted to contact and provide constrain to a ribbon 101that passes the constraining wheels 355 as described further below. Asbest shown in FIGS. 18 and 20, the constraining wheels 355 are adaptedto rotate about a first axis of rotation 357. Only one, or more thantwo, constraining wheels may be employed.

The constraining wheel unit 291 a includes a lever 359 that is coupledto the constraining wheels 355 and adapted to rotate about a second axisof rotation 361 that is offset from the first axis of rotation 357 ofthe constraining wheels 355 (e.g., by an offset 363). In this manner, asthe lever 359 is rotated into a lock position (as shown in FIGS. 17 and18), the first axis of rotation 357 of the constraining wheels 355 ismoved toward an edge 365 of the housing 351, thereby moving theconstraining wheels 355 into an extended position (and into contact witha ribbon 101 passing through a housing section 271 (FIG. 13A) to whichthe constraining wheel unit 291 a is coupled). Likewise, as the lever359 is rotated into a load position (as shown in FIGS. 19 and 20), thefirst axis of rotation 357 of the constraining wheels 355 is moved awayfrom the edge 365 of the housing 351, thereby moving the constrainingwheels 355 into a retracted position (and out of contact with a ribbon101 passing through the housing section 271 to which the constrainingwheel unit 291 a is coupled). The offset 363 may be determined, forexample, based on the distance that the constraining wheels 355 mustextend to contact a ribbon 101. In at least one embodiment, the offsetmay be about 3 mm, although other offsets may be employed.

In operation, the constraining wheel unit 291 a is coupled to a housingunit 271 of support system 269 (not shown in FIGS. 17–20), such as atone of the second openings 275 of FIG. 13A. The lever 359 is rotatedinto a lock position (FIGS. 17 and 18) so that the constraining wheels355 are brought into contact with a first side of a vertical portion 103of a ribbon 101 (not shown) that passes through the housing section 271.When the housing section 271 is a straight section, a secondconstraining wheel unit 291 a (not shown) preferably is employed so thata second pair of constraining wheels 355 (not shown) contact a secondside of the vertical portion 103 of the ribbon 101 that is opposite thefirst side of the vertical portion 103. In this manner, lateral motionof the ribbon 101 as it rotates may be limited by the constraining wheelunits 291 a.

The constraining wheels 355 may be replaced while a ribbon 101 is inmotion by (1) moving the lever 359 from the lock position (FIGS. 17 and18) to the load position (FIGS. 19 and 20) so that the constrainingwheels 355 retract from the ribbon 101; (2) removing the constrainingwheel unit 291 a from the housing section 271 (FIG. 13A) to which theconstraining wheel unit 291 a is coupled; and (3) replacing theconstraining wheels 355. Only one constraining wheel 355 need bereplaced if desired. The constraining wheels 355 may then be broughtback into contact with the ribbon by reattaching the constraining wheelunit 291 a to the housing section 271 and moving the lever 359 to thelock position (FIGS. 17 and 18).

FIGS. 21 is a perspective front view of a second exemplary embodiment ofthe constraining wheel unit 291 of FIG. 13B, referred to as constrainingwheel unit 291 b in FIG. 21. The constraining wheel unit 291 b issimilar to the constraining wheel 291 a of FIGS. 17–20, but does notemploy a lever 359 to move the constraining wheels 355 between a lockand a load position. Rather, the constraining wheels 355 remained fixedrelative to the housing 351 of the constraining wheel unit 291 b.

The constraining wheels 355 of the constraining wheel unit 291 b may bereplaced while a ribbon is in motion (and is being constrained by thewheels 355) by removing the constraining wheel unit 291 b from thehousing section 271 (FIG. 13A) to which the constraining wheel unit 291b is coupled and then replacing the constraining wheels 355. Only oneconstraining wheel 355 need be replaced if desired. The constrainingwheels 355 may then be brought back into contact with the ribbon byreattaching the constraining wheel unit 291 b to the housing section271. (For example, the constraining wheel unit 291 b may be detachedfrom/attached to the housing section 271 via fasteners 353.)

FIG. 22 is a perspective front view of a third exemplary embodiment ofthe constraining wheel unit 291 of FIG. 13B, referred to as constrainingwheel unit 291 c in FIG. 22. The constraining wheel unit 291 c issimilar to the constraining wheel 291 b of FIG. 21, but only employs asingle constraining wheel 355. For example, a first constraining wheelunit 291 c may be employed to constrain a top portion of a first side ofa vertical portion 103 of a ribbon 101 (not shown) and a similar, secondconstraining wheel unit 291 c may be positioned below the firstconstraining wheel unit 291 c and employed to constrain a bottom portionof the first side of the vertical portion 103 of the ribbon 101. Theconstraining wheels 355 of the first and second constraining wheel units291 c thereby may be replaced independently of one another. For example,the constraining wheel 355 of the constraining wheel unit 291 c of FIG.22 may be replaced while a ribbon is in motion by removing theconstraining wheel unit 291 c from the housing section 271 to which theconstraining wheel unit 291 c is coupled and then replacing theconstraining wheels 355. The constraining wheel 355 may then be broughtback into contact with the ribbon by reattaching the constraining wheelunit 291 c to the housing section 271. (For example, the constrainingwheel unit 291 c may be detached from/attached to the housing section271 via fasteners 353).

Exemplary Inventive Support Wheel Unit

FIG. 23 is a front perspective view of an exemplary embodiment of thesupport wheel unit 289 of FIG. 13B, referred to as support wheel unit289 a in FIG. 23. With reference to FIG. 23, the support wheel unit 289a includes a first housing portion 369 that is hingedly coupled to asecond housing portion 371. A support wheel 373 is rotatably coupled tothe second housing portion 371. The first and second housing portions369, 371 are adapted to couple to a housing section 271 of supportsystem 269 (e.g., the first opening 273 of housing section 271 in FIG.13A, such as via one or more bolts, screws or other fastenersrepresented generally by reference numeral 375 in FIG. 23).

In operation, to support a ribbon 101 (not shown) employing the supportwheel unit 289 a, the support wheel unit 289 a is coupled to a housingsection 271 (e.g., at a first opening 273 of housing section 271 of FIG.13A). With both the first and second housing portions 369, 371 coupledto the housing section 271, the support wheel 373 extends into thehousing section 271 and contacts and supports a first side of ahorizontal portion 105 of the ribbon 101 as the ribbon rotates. Numerousof such support wheel units may be employed to support the rotatingribbon at other locations along the ribbon. If the ribbon 101 beingsupported has a horizontal portion 105 on both sides of the verticalportion 103 of the ribbon 101, one or more support wheel units may becoupled on both sides of the housing section 271 (FIG. 13B) so that thesupport wheel units support the ribbon 101 on both sides of the verticalportion 103 of the ribbon 101.

The support wheel 373 may be replaced while the ribbon is in motion by(1) unfastening the fasteners 375 of the second housing portion 371 ofthe support wheel unit 289 a; (2) pivoting the second housing portion371 (and thus the support wheel 373) away from the ribbon; and (3)replacing the support wheel 373. The support wheel 373 then may bebrought back into contact with the ribbon by reattaching the secondhousing portion 371 to the housing 271 section.

It will be understood that the embodiments of the housing sections 271,driving wheel systems 284, support wheel units 289, and/or constrainingwheel units 291 described above are merely exemplary, and that otherapparatus may be employed to similarly house, drive, support and/orconstrain a ribbon in accordance with the present invention. Each wheelemployed with the inventive driving wheel systems 284, support wheelunits 289, and/or constraining wheel units 291 may be the same or adifferent type of wheel. In at least one embodiment of the invention,each wheel of the driving wheel systems 284, support wheel units 289,and constraining wheel units 291 may comprise an in-line skate wheel.Any other suitable wheel/rotating member and/or material may besimilarly employed (e.g., high density polyethelene wheels).

Exemplary Implementation of an Inventive Conveyor System

In accordance with the present invention, an inventive conveyor system,such as one of the conveyors 106, 121 or 155 of FIGS. 2–4, may beimplemented employing one or more of the ribbons 101 a–n describedherein and one or more housing sections (e.g., housing section 271(FIGS. 13A–B)), one or more driving wheel systems (e.g., driving wheelsystem 284 (FIGS. 13B–16)), one or more support wheel units (e.g.,support wheel units 289 (FIGS. 13B and 23)) and/or one or moreconstraining wheel units (e.g., constraining wheel units 291 (FIGS. 13Band 17–22)) described herein. For example, a ribbon 101 may be employedto form a simple or serpentine closed loop that is (1) housed within aplurality of straight and/or curved housing sections 271; (2) driven byone or more driving wheel units 285; (3) supported by one or moresupport wheel units 289; and (4) constrained by one or more constrainingwheel units 291.

By orienting the ribbon so that a thick portion of the ribbon resideswithin a vertical plane and a thin portion of the ribbon resides withina horizontal plane, the ribbon is flexible in the horizontal plane andrigid in the vertical plane. Such a configuration allows the inventiveconveyor to be constructed and implemented inexpensively (e.g., becausethe high aspect ratio ribbon is easy and inexpensive to manufacture).Because the driving wheels may contact and drive the ribbon along avertical portion of the ribbon, and the support wheels may contact andsupport the ribbon along a horizontal portion of the ribbon, the drivingmechanism for the ribbon is decoupled from the supporting mechanism forthe ribbon and each may be serviced independently. Further, drivingwheels, support wheels and constraining wheels may be replaced while theribbon is in motion (e.g., reducing conveyor system downtime andincreasing substrate throughput).

The number of housing sections 271, driving wheel units 285, supportwheel units 289 and constraining wheel units 291 employed within aconveyor system depends on numerous factors such as length and/orthickness of the ribbon 101, the path traveled by the ribbon 101, theweight of the ribbon 101, the weight to be transported by the ribbon 101(e.g., the number/weight of substrate carriers to be transported by theribbon 101), how fast the ribbon 101 rotates, the amount of lateralstability required for the ribbon 101, etc. In one particular embodimentof an inventive conveyor system, constraining wheels 355 (ofconstraining wheel units 291) are spaced along and contact a verticalportion of a ribbon about every 20 inches along curved portions of theribbon and about every 20–23 inches along straight portions of theribbon. Support wheels 373 (of support wheel units 289) are positionedbetween each constraining wheel unit 291 and contact and support thehorizontal portion of the ribbon. In certain applications, such aconstraining wheel 355 and support wheel 373 spacing may produce apeak-to-peak lateral displacement of the ribbon of less than about 3 mm.In locations of a semiconductor device manufacturing facility in which asubstrate carrier is to be loaded onto or removed from the ribbon (e.g.,above a processing tool, a substrate loading station or at locations atwhich a substrate carrier may be transferred to or from another ribbon),a tighter tolerance in peak-to-peak lateral displacement of the ribbonmay be required. For example, in some cases, a 0.5 mm or lesspeak-to-peak lateral displacement of the ribbon may be achieved byspacing constraining wheels 355 about every 10 inches along the ribbon(and by positioning support wheels 373 therebetween as described above).Other constraining wheel and/or support wheel spacings may be employed,as may other peak-to-peak lateral displacements for a ribbon.

In one or more embodiments of the invention, approximately ⅜ horsepowermotors (of driving wheel units 285) are placed about every 28 feet alonga ribbon 101 and are employed to drive driving wheels 331 of the drivingwheel units 285. Other motor sizes and spacings may be employed (e.g.,depending on the weight of the ribbon and/or substrate carrierstransported by the ribbon, the resistance supplied by the driving,supporting and/or constraining wheels, etc.).

As described previously, each inventive ribbon 101 may be adapted totransport a plurality of substrate carriers within at least a portion ofa semiconductor device manufacturing facility. For example, each ribbonmay have a plurality of supports or cradles rigidly coupled to theribbon, each adapted to support and transport a substrate carrier withinthe semiconductor device manufacturing facility (e.g., between substrateloading stations of processing tools). As with the ribbon 101 k of FIG.5, each other inventive ribbon 101 may comprise surface indicia, such asthe one or more vertically-oriented slots 195 in FIG. 5, and mountingfeatures, such as the holes 197 in FIG. 5, arranged at regular intervalsalong the length L of the ribbon 101 to respectively (1) identify thelocation of substrate carriers being transported by the ribbon 101; and(2) provide a secure and/or rigid mounting location for the supports orcradles for the substrate carriers. Because the location of eachsubstrate carrier support/cradle is fixed relative to the ribbon 101,knowing the position of the ribbon 101 as it rotates providesinformation about the position of a substrate carrier (supported by acradle/support rigidly coupled to the ribbon 101) being transported bythe ribbon 101 and vice versa. Separate ribbon position sensors andsubstrate carrier position sensors need not be employed.

FIG. 24 is an exemplary embodiment of a sixth exemplary ribbon 101 padapted to transport a plurality of substrate carriers 501 a–e. Theribbon 101 p includes a vertical portion 103 p and a horizontal portion105 p, and may be configured, for example, in accordance with any of theinventive ribbons described herein. A plurality of substrate carriersupports 503 a–e are coupled to the ribbon 101 p, and may comprisecradles or other support members adapted to support the substratecarriers 501 a–e during transport.

As shown, the vertical portion 103 p of the ribbon 101 p includes setsof openings or slots 505 a–e each positioned above one of the substratecarrier supports 503 a–e, respectively. In the particular embodimentshown, the first set of slots 505 a includes three slots, while theremaining sets of slots 505 b–e include two slots per set. Other numbersof slots per set may be employed.

Each set of slots 505 a–e is configured to allow a beam of light (notshown) to pass through the vertical portion 103 p of the ribbon 101 pabove a substrate carrier support 503 a–e. At all other locations on theribbon 101 p, the beam of light is blocked by the ribbon 101 p.Accordingly, by monitoring and detecting the light beam as it passesthrough the ribbon 101 (e.g., via a detector and/or a controller notshown), the position of the ribbon 101 p, a substrate carrier support503 a–e and/or a substrate carrier 501 a–e may be determined. Further,by monitoring and detecting the different light beam pattern generatedby the first set of slots 505 a relative to the remaining sets of slots505 b–e, the “front” or some other reference position of the ribbon 101p may be determined (whether or not the ribbon 101 p forms a closedloop). If the spacing between each substrate carrier support 503 a–e isknown, such a reference position may be employed to determine theposition of each substrate carrier 501 a–e/substrate carrier support 503a–e (e.g., even if the other sets of slots 505 b–e are not present).

Knowledge of the position of each substrate carrier 501 a–e and/orsubstrate carrier support 503 a–e also may be employed todetermine/monitor speed of the ribbon 101 p. For example, by determininga time between successive breakings of a light beam by any of the slotsof one of the sets 505 a–e, or between slot sets 505 a–e, speed of theribbon may be determined (e.g., by a controller (not shown) havinginformation regarding spacing between slots of sets and/or slot sets).Other opening shapes or surface features (e.g., reflective features)also may be employed to determine ribbon, substrate carrier supportand/or substrate carrier position and/or speed.

With knowledge of substrate carrier position, substrate carriers 501 a–emay be loaded onto or unloaded from the ribbon 101 p (e.g., whether ornot the ribbon 101 p is in motion). In at least one embodiment of theinvention, substrate carriers 501 a–e may be loaded onto or unloadedfrom the ribbon 101 p while the ribbon 101 p is in motion as describedfor example, in previously incorporated U.S. patent application Ser. No.10/650,481, filed Aug. 28, 2003 and titled “Method and Apparatus forUnloading Substrate Carriers from Substrate Carrier Transport Systems”or U.S. patent application Ser. No. 10/650,480, filed Aug. 28, 2003 andtitled “Substrate Carrier Handler That Unloads Substrate CarriersDirectly From a Moving Conveyor”. Other apparatus/systems also may beemployed.

The ribbon 101 p (and any other inventive ribbons described therein)thus is an “encoded” ribbon or band that contains encoded informationsuch as band speed, substrate carrier position, substrate carrierhand-off locations, etc., that may be read and seen by multiple tools,such as the substrate loading station described in previouslyincorporated U.S. patent application Ser. No. 10/650,480, filed Aug. 28,2003 and titled “Substrate Carrier Handler That Unloads SubstrateCarriers Directly From a Moving Conveyor” (e.g., a high speed, baydistributed stocker). Such substrate carrier loading stations may act as“slaves” to the “master” ribbon/conveyor, measuring conveyor speed,substrate carrier position, hand-off positions, etc., from theribbon/conveyor. A system with distributed intelligence (e.g., eachsubstrate carrier loading station and/or the conveyor) thereby may beprovided. Each tool may have a read head (e.g., a plurality of sensorsthat read the slots or openings in the band to determine band speed,substrate carrier position, hand-off positions, etc.) that reads encodedinformation on the inventive ribbon (e.g., a central encoder thatincludes information stored via the placement/positioning of theslots/openings in the band such as the slot sets 505 a–e).

It should be noted that while substrate carriers are being transportedwithin a semiconductor device manufacturing facility on the ribbon-basedconveyor system of the present invention, the vertical, longitudinal (inthe direction of the conveyor), and horizontal (side-to-side from theline of the conveyor) positions of the ribbon may be determined and/orcontrolled to a high degree of accuracy. In this manner, transfer ofsubstrate carriers from or to the conveyor system, while the conveyorsystem is in motion, is facilitated.

The dimensions of the driving, support and/or constraining wheels can beinspected both as new, such as before installation, and after theconveyor system has been in operation (e.g., to check for wear).Adjustments to position of the driving, support and/or constrainingwheels thereafter may be performed to ensure/retain tight control overthe vertical, longitudinal and/or horizontal positions of the conveyorsystem. For example, the axis of rotation of the support wheels can becontrolled for proper vertical position and/or horizontal orientation ofthe ribbon of the conveyor system, such as by position adjustment means(screws, adjustable spacers or the like, not shown) between the housingsection 271 and the support wheels. Holding to tight tolerances withinand between conveyor system components such as the driving, supportand/or constraining wheels (e.g., through frequent inspections and/orreplacements), may reduce or eliminate the need for such adjustability.

Although a ribbon comprising a continuous piece of material throughoutits entire length is advantageous in certain implementations, aplurality of connectable longitudinal sections can be employed to form aribbon, for example as part of a custom installation in order to providea desired path for the ribbon. In one or more embodiments of theinvention, overall length of the ribbon may be of little concern;rather, it may be more important to ensure that the ribbon coincideswith paths set by semiconductor device processing tools arranged, forexample, in one or more straight lines in a manufacturing facility. Assuch, the radius of the ribbon as it turns between the straight-linepaths of processing tools may be variable. The length of the ribbon maytherefore vary with the selected radius or radii of the ribbon. Inaddition, the ribbon may be housed along its entire length; or certainportions of the ribbon may not be housed by a housing section. Also,instead of housing sections passing through a gap in a driving wheelunit support, two separate housing sections may interface with/at adriving wheel unit support, and the driving wheel unit support may besuspended in a manner similar to the housing section supports describedpreviously.

In at least one embodiment of the invention, all serviceable parts ofthe inventive conveyor system may be serviced while the conveyor (e.g.,ribbon) is in motion. For example, all wheels, motors, motion drivers,band controllers, etc., may be replaced while the conveyor system is inmotion. Further, significant redundancy may be built into each of thesecomponents so that one or more wheels, motors, motion drivers, bandcontrollers, etc., may fail without affecting (or significantly)affecting motion of the conveyor system. That is, the conveyor systemmay be maintained in motion despite failure of one or more supporting,driving, controlling, etc., components. Spacing of wheels and/or othercomponents may be such that each may be replaced while still meetingsystem requirements for support, drive force, etc.

In addition to transporting single substrate carriers, the inventiveconveyor system may be used to transport substrate carriers thattransport multiple substrates. Further, substrate carriers need not besealed (e.g., may be opened on one or more sides).

The inventive conveyor system may include a ribbon that is verticallysupported from underneath (e.g., from underneath a vertical portion ofthe ribbon). The ribbon may be supported by any means (e.g.,magnetically, via air bearings, etc.).

As stated, selection of the material used for any of the ribbons 101 maybe based on numerous factors such as material strength, flexibility,fatigue rate, cost, etc. Exemplary materials that may be employed forany of the inventive ribbons described herein include stainless steel,polycarbonate, composite materials (e.g., carbon graphite, fiberglass,etc.), steel or otherwise reinforced polyurethane, epoxy laminates,plastic or polymer materials that include stainless steel, fabric (e.g.,carbon fiber, fiberglass, Kevlar® available from Dupont, polyethelene,steel mesh, etc.) or another stiffening material, etc. In one particularembodiment, a ribbon may be constructed using a single or multi-piecemolded or extruded material such as extruded polyurethane with a steelreinforcing cable or glass filled polyurethane inserts. A multi-pieceribbon may be laminated to form a single piece construction (e.g., bybonding stainless steel sheets to plastic). Any other suitableconfiguration may be employed.

In one embodiment of the invention, the vertical portion of the ribbonmay comprise 301 stainless steel (half hard) having a thickness of about0.05 inches. The horizontal portion may comprises approximately 1 inchwide 6061-T6 aluminum pieces attached to the vertical portion (e.g., viarivots or another mechanism) and spaced by about 0.06 inches. Such aribbon may be similar to the ribbon described previously with referenceto FIG. 12. Other materials and/or dimensions may be employed.

FIGS. 25A and 25B are a perspective view and a side view, respectively,of a seventh exemplary ribbon 101 q provided in accordance with thepresent invention. With reference to FIGS. 25A–B, the ribbon 101 qincludes a T-section 600 (which forms the vertical portion 103 q and thehorizontal portion 105 q of the ribbon 101 q) formed from glass fillednylon, a rigid plastic, cast aluminum or the like. The horizontalportion 105 q includes serpentine gaps 602 that allow the ribbon 101 qto bend (in a horizontal plane) and provide a smooth transition for thesupport wheels used to support the ribbon 101 q. The vertical portion103 q includes a thickened section 603 formed from a plurality ofinterleaved fingers 605 that form a relatively incompressible drivingsurface for the driving wheels that are employed to drive the ribbon 101q.

Two belts 607, 609 are attached to the vertical portion 103 q above andbelow the thickened section 603 as shown, and may be attached thereto byany suitable mechanism (e.g., bolts, rivots, adhesives or the like). Inone embodiment of the invention, the belts 607, 609 may be formed ofpolyurethane or a similar material (e.g., reinforced with steel cords orthe like).

While the inventive ribbons have been described herein primarily ashaving a single horizontal portion (e.g., a portion 105), it will beunderstood that each ribbon may include more than one horizontalportion. For example, providing a horizontal portion near both a top andbottom of a ribbon, forming a double “T”-type configuration, tends tobalance the bending moment of the ribbon (within a horizontal plane). Insuch an embodiment, lower support wheels may be employed to contact thebottom horizontal portion and stabilize the ribbon (and any substratecarrier supported thereon) in turns and critical transfer areas. Suchlower support wheels may be similar to the support wheels 373 of thesupport wheel unit 289 a of FIG. 23, or otherwise configured.

FIG. 26 is a perspective view of an eighth ribbon 101 r provided inaccordance with the present invention. The eighth ribbon 101 r includesa vertical portion 103 r and two horizontal portions 105 r, 105 r′. Theupper horizontal portion 105 r is adapted to support the load of theribbon 101 r (e.g., via support wheels previously described); and thelower horizontal portion 105 r′ allows the ribbon 101 r to bend moresymmetrically. In at least one embodiment of the invention, the ribbon101 r is formed of polyeurethane (e.g., 92 durometer poly) or a similarmaterial. The ribbon 101 r may be reinforced with steel cords, fabricsor similar structural features 701. In such an embodiment, lower supportwheels may be employed to contact the lower horizontal portion 105 r′and stabilize the ribbon 101 r (and any substrate carrier supportedthereon) in turns and critical transfer areas. Gaps or notches 703 areformed in the horizontal portions 105 r, 105 r′ to assist in bending ofthe ribbon 101 r. The ribbon 101 r may be formed as a single piece orfrom multiple pieces (e.g., a plurality of extruded portions that arelaminated together). As shown in FIG. 26, horizontal or other features704 may be formed in the ribbon 101 r to provide additional support forsubstrate carriers being transported by the ribbon 101 r.

As stated, the support wheels 373 (FIG. 23) are adapted to support aribbon via contact with a horizontal portion of the ribbon. Whiledescribed herein a primarily passive (e.g., non-driven), it will beunderstood that one or more of the support wheels 373 may be driven inaddition to or in place of the driving wheels 331 a and/or 331 b. One ormore support wheels 373 thereby may drive a ribbon through contact witha horizontal portion of the ribbon. For a flat horizontal portion, anopposing wheel may be employed opposite a driven support wheel (e.g., tomaintain contact pressure on the driven support wheel). Likewise, one ormore of the constraining wheels 355 may be similarly driven.

To provide two independent driving points at or near one location, drivelocations on each side of a ribbon may be offset slightly. For example,the first set of wheels 331 a of a driving wheel unit support 287 a maybe offset slightly along a length of a ribbon relative to the second setof wheels 331 b of the driving wheel unit support 287 a. In one or moreembodiments of the invention, a ribbon may include surface features suchas teeth that engage wheels, gears or other driving mechanisms thatdrive the ribbon. Such features may be formed on a vertical and/orhorizontal portion of the ribbon. FIG. 26 illustrates a plurality ofteeth 705 formed on (e.g., molded in) at least one side of the verticalportion 103 r of the ribbon 101 r. Such teeth 705 may be engaged by adriving wheel and employed to drive the ribbon 101 r (e.g., in a rackand pinion or other similar arrangement).

To minimize drive motor interactions and protect a driven ribbon, aunidirectional drive clutch may be employed for each drive motor 311(e.g., such that torque may only be applied in one direction). In thismanner, if a motor bearing seizes during operation, a rotating ribbonmay back drive the affected drive wheel 311 rather than allow the drivewheel 311 to skid or slide along a surface of the ribbon. A ribbon maybe adapted to carry substrates or substrate carriers. A ribbon may carrysingle substrate carriers, substrate carriers adapted to house more thanone substrate (e.g., multiple substrate carriers) or a combination ofdifferent size substrate carriers (e.g., single and multiple substratecarriers).

Accordingly, while the present invention has been disclosed inconnection with exemplary embodiments thereof, it should be understoodthat other embodiments may fall within the spirit and scope of theinvention as defined by the following claims.

1. A conveyor system adapted for use in delivering substrate carrierswithin a semiconductor device manufacturing facility comprising: aribbon that forms a closed loop along at least a portion of thesemiconductor device manufacturing facility, the ribbon adapted to; beflexible in a horizontal plane and rigid in a vertical plane; andtransport a plurality of substrate carriers within the at least aportion of the semiconductor device manufacturing facility; wherein theribbon comprises: a vertical portion adapted to support substratecarriers; and a horizontal portion that extends outward from thevertical portion so as to create a supporting surface adapted to supporta weight of the ribbon.
 2. The conveyor system of claim 1 wherein thevertical and horizontal portions are formed from a single piece ofmaterial.
 3. The conveyor system of claim 1 wherein the vertical andhorizontal portions are formed from separate pieces of material.
 4. Theconveyor system of claim 3 wherein the horizontal portion comprises aplurality of horizontal sections coupled to the vertical portion.
 5. Theconveyor system of claim 1 wherein the horizontal portion comprises aplurality of slots adapted to increase flexibility of the ribbon in ahorizontal direction.
 6. The conveyor system of claim 5 wherein theplurality of slots are evenly spaced along the ribbon.
 7. The conveyorsystem of claim 1 wherein the ribbon comprises stainless steel.
 8. Theconveyor system of claim 1 wherein the ribbon comprises a verticalportion having a first feature adapted to identify a beginning of theribbon.
 9. The conveyor system of claim 8 wherein the first featurecomprises at least a first opening formed through the vertical portion.10. The conveyor system of claim 8 wherein the vertical portion of theribbon further comprises a plurality of second features, each secondfeature adapted to identify a location at which a substrate carrier maybe held and transported by the ribbon.
 11. The conveyor system of claim10 wherein each second feature comprises at least a second openingformed through the vertical portion.
 12. The conveyor system of claim 11wherein the at least a first opening comprises a first plurality ofopenings and wherein the at least a second opening comprises a secondplurality of openings.
 13. The conveyor system of claim 1 furthercomprising a plurality of supports rigidly coupled to the ribbon, eachsupport adapted to support and transport a substrate carrier within theat least a portion of the semiconductor device manufacturing facility.14. The conveyor system of claim 1 wherein the ribbon is adapted totransport single substrate carriers.
 15. A conveyor system adapted foruse in delivering substrate carriers within a semiconductor devicemanufacturing facility comprising: a ribbon that forms a closed loopalong at least a portion of the semiconductor device manufacturingfacility, the ribbon adapted to: be flexible in a horizontal plane andrigid in a vertical plane; transport a plurality of substrate carrierswithin the at least a portion of the semiconductor device manufacturingfacility; and continuously rotate; wherein the ribbon comprises: avertical portion adapted to support substrate carriers; and a horizontalportion that extends outward from the vertical portion so as to create asupporting surface adapted to support a weight of the ribbon.
 16. Theconveyor system of claim 15 wherein the ribbon comprises stainlesssteel.
 17. The conveyor system of claim 15 wherein the ribbon comprisesa vertical portion having a first feature adapted to identify abeginning of the ribbon.
 18. The conveyor system of claim 17 wherein thevertical portion of the ribbon further comprises a plurality of secondfeatures, each second feature adapted to identify a location at which asubstrate carrier may be held and transported by the ribbon.
 19. Theconveyor system of claim 15 further comprising a plurality of supportsrigidly coupled to the ribbon, each support adapted to support andtransport a substrate carrier within the at least a portion of thesemiconductor device manufacturing facility.
 20. The conveyor system ofclaim 15 wherein the ribbon is adapted to transport single substratecarriers.
 21. A conveyor system adapted for use in delivering substratecarriers within a semiconductor device manufacturing facilitycomprising: a ribbon that forms a closed loop along at least a portionof the semiconductor device manufacturing facility, the ribbon adaptedto: be flexible in a horizontal plane and rigid in a vertical plane; andcontinuously rotate; and a plurality of supports rigidly coupled to theribbon, each support adapted to support and transport a substratecarrier within the at least a portion of the semiconductor devicemanufacturing facility; wherein the ribbon comprises: a vertical portionadapted to support substrate carriers; and a horizontal portion thatextends outward from the vertical portion so as to create a supportingsurface adapted to support a weight of the ribbon.
 22. The conveyorsystem of claim 21 wherein the ribbon comprises stainless steel.
 23. Theconveyor system of claim 21 wherein the ribbon comprises a verticalportion having a first feature adapted to identify a beginning of theribbon.
 24. The conveyor system of claim 23 wherein the vertical portionof the ribbon further comprises a plurality of second features, eachsecond feature adapted to identify a location at which a substratecarrier may be held and transported by the ribbon.
 25. The conveyorsystem of claim 21 wherein the ribbon is adapted to transport singlesubstrate carriers.
 26. A conveyor system adapted for use in deliveringsubstrate carriers within a semiconductor device manufacturing facilitycomprising: a ribbon that forms a closed loop along at least a portionof the semiconductor device manufacturing facility; and a plurality ofsupports rigidly coupled to the ribbon, each support adapted to supportand transport a single carrier within the at least the portion of thesemiconductor device manufacturing facility; wherein the ribboncomprises: a vertical portion adapted to support substrate carriers; anda horizontal portion that extends outward from the vertical portion soas to create a supporting surface adapted to support a weight of theribbon.
 27. The conveyor system of claim 26 wherein the ribbon isadapted to continuously rotate during transport and delivery ofsubstrate carriers.
 28. The conveyor system of claim 26 wherein theribbon comprises stainless steel.
 29. The conveyor system of claim 26wherein the ribbon comprises a vertical portion having a first featureadapted to identify a beginning of the ribbon.
 30. The conveyor systemof claim 29 wherein the vertical portion of the ribbon further comprisesa plurality of second features, each second feature adapted to identifya location at which a substrate carrier may be held and transported bythe ribbon.
 31. The conveyor system of claim 26 wherein the ribbon isadapted to transport single substrate carriers.
 32. A method oftransporting substrate carriers comprising: forming a closed loop alongat least a portion of a semiconductor device manufacturing facility witha ribbon, the ribbon adapted to be flexible in a horizontal plane andrigid in a vertical plane and having: a vertical portion adapted tosupport substrate carriers; and a horizontal portion that extendsoutward from the vertical portion so as to create a supporting surfaceadapted to support a weight of the ribbon; and transporting a substratecarrier within the at least a portion of the semiconductor devicemanufacturing facility with the ribbon.
 33. The method of claim 32wherein the ribbon comprises stainless steel.
 34. The method of claim 32wherein the ribbon comprises a vertical portion having a first featureadapted to identify a beginning of the ribbon.
 35. The method of claim34 wherein the vertical portion of the ribbon further comprises aplurality of second features, each second feature adapted to identify alocation at which a substrate carrier may be held and transported by theribbon.
 36. The method of claim 32 further comprising rigidly coupling aplurality of supports to the ribbon, each support adapted to support andtransport a substrate carrier within the at least a portion of thesemiconductor device manufacturing facility.
 37. The method off claim 32wherein transporting substrate carriers comprises transporting singlesubstrate carriers.